Devices and methods for parameter measurement

ABSTRACT

A thin-film, diaphragm based device is disclosed which can be used to perform an array of sensing and actuating operations where a very thin profile is desired, such as in millimeter, micrometer, or nanometer tight spaces.

The application claims priority to U.S. Provisional Patent ApplicationNo. 61/914,473 filed Dec. 11, 2013, which is incorporated herein byreference in its entirety.

BACKGROUND INFORMATION

Most MEMS sensors are built onto silicon based wafers of approximately500 μm thickness. While these thick substrates confer stability duringfabrication and over the long term, the thickness limits applications intight spaces, which includes many biomedical and industrial conditions.The rigidity and biocompatibility of silicon based sensors areadditional limiting factors. Overcoming these issues is particularlychallenging for diaphragm based sensors, due to the tight controlrequired to build three-dimensional cavities and diaphragms at such asmall scale.

The active region of many silicon based sensors is the deflectingdiaphragm near the surface of the sensor. Typically, the active regionranges from the low-micron to sub-micron scale, which is a smallfraction of the overall sensor thickness. The sensor profile can besignificantly reduced if the inactive substrate is replaced with athinner substrate or if the active region is integrated into the devicepackage.

Passive ultrasonic sensors, methods and systems for their use aredescribed in U.S. Pat. No. 6,770,032. Specifically, passive acousticsensors having at least two flat parallel acoustically reflectingsurfaces. At least one reflecting surface is on a member which ismovable such that the distance between the reflecting surfaces varies asa function of a physical variable to be determined Preferably, thesensor is made such that the intensity of a first portion of incidentacoustic waves which is reflected from one reflecting surface is equalor substantially similar to the intensity of a second portion of theincident acoustic waves which is reflected from the other reflectingsurface. The first portion and the second portion interfere to form areturning acoustic signal having one or more maximally attenuatedfrequencies which is correlated with the value of the physical variable.The internal acoustic signal is received and processed to determine thevalue of the physical variable from one or more of the maximalattenuation frequencies. Methods and systems for using the passivesensors are disclosed.

Existing systems such as those described above use an ultrasound probe,with a limited transmitting/receiving bandwidth, which permitted limitedsensing of resonators, because most feasible mechanical resonators havenatural frequencies in the audible or just above audible range underphysiologically relevant pressure.

A passive sensor system using ultrasonic energy is also described in PCTPatent Publication WO 1995020769. In particular, a passive sensor system(14) utilizing ultrasonic energy is disclosed. The passive sensor systemincludes at least one ultrasonically vibratable sensor (10) and anultrasonic activation and detection system (20, 22, 24, 25). The sensor(10) has at least one vibration frequency which is a function of aphysical variable to be sensed. The ultrasonic activation and detectionsystem (20, 22, 24, 25) excites the sensor and detects the vibrationfrequency from which it determines a value of the physical variable. Thesensor includes (see FIG. 2-4) a housing, a membrane which is attachedto the housing and which is responsive to the physical variable, avibratable beam attached to the housing at one end and a coupler,attached to the membrane and to a small portion of the vibratable beam,which bends the vibratable beam in response to movement of the membrane.

The ability to measure pressure locally can be used in the analysis ofcertain conditions. Diabetics are prone to foot ulceration, with apopulation prevalence of approximately 8% and a lifetime risk of up to25% (Margolis, Boulton). Loss of innervation due to diabetic peripheralneuropathy induces muscle laxity and associated skeleton deformities, aswell as loss of sensation. This increased risk of focal stress pointsand reduced ability to accommodate to the initiating trauma greatlycontribute to the formation of ulcers, which can progress in severity tothe point where amputation is necessary. Critically, prevention andmanagement by proper monitoring of foot conditions could reduceamputations by 50% (Driver).

Treatment of an ulcer is difficult after formation due to repetitivedamage and compromised healing in diabetics. Over a third of the directexpenditure on diabetes in the US ($116 billion) is on ulcer treatment,with each treatment costing on average $28,000. Prevention by carefulmonitoring of the condition of the feet is considered to be the bestapproach and is thought to potentially avert half of the amputations dueto ulceration (Driver).

Space constrictions limit conventional sensing devices in manyenvironments, such as in shoes or insoles. Wires, power supplies,circuitry, and antennas in conventional approaches are all too large andcumbersome to fit without disruption. Electromagnetic resonance sensingoffers a solution because these simple wireless systems only require acoil and a capacitor to operate. As such, they can be made small enoughto wirelessly sense otherwise inaccessible environments. They areinterrogated wirelessly by magnetic coupling. In some cases, theresonant system can entirely replace the conventional radio link system;in other cases, it can be used together with a radio link to extend thesensing range. The mechanism of resonance sensing is not widely used orknown, probably because most sensing environments are accessible viawired sensors. Presently, to synthesize this mechanism of sensing withan application in foot pressure sensing requires a breadth of knowledgein a numerous disparate fields, including physics, mechanics, electricalengineering, and clinical medicine.

Peripheral neuropathy contributes to the high prevalence of footulceration in diabetics. Several systems, integrated into shoe insolesand socks, are currently available for monitoring foot pressures toprevent ulceration. However, these systems have practical limitationsand inconveniences for end user, such as dangling wires or tenuouselectronics.

Embodiments of the present disclosure offer a clean solution through aresonant wireless system in a shoe insole. The sensing insole isphysically simple and durable, requires no on-site power supply orcircuitry, and can wirelessly transmit pressure signals to a nearbydevice with radio link capability, such as a clip on the outer shoe, ananklet, or a waist belt. To our knowledge, no resonant wireless sensingsystem has been applied to measuring foot pressures in the patent orscientific literatures. An embodiment has been enabled with a thin filmcapacitive pressure transducer which demonstrates functionality andexcellent pressure sensitivity.

SUMMARY

Described herein is a thin-film, diaphragm based device which can beused to perform an array of sensing and actuating operations anywherewhere a very thin profile is desired, such as in millimeter, micrometer,or nanometer tight spaces. The device has a diaphragm and can operate bycapacitive, resistive, and resonant mechanisms. Due to its generalstructure, applications include: mechanical sensing and actuation,chemical-biological sensing, and optical sensing.

The device can be bonded to any substrate, allowing for deviceintegration. Additionally, the device can be constructed from flexiblematerials, which allows for applications which require flexibility,conformation to a nonflat or mobile surface, or in three dimensionalconfigurations. The device can also be fabricated as an array ofdiaphragms to measure single factors, to measure multiple factorssimultaneously, or to measure surface maps of factors. The fields ofapplication are wide ranging, from biomedical to industrial. The thinfilm sensor can be considered a platform technology for low profile MEMSsensing due to its general structure and utility.

The dimensions and materials of commercially available pressuretransducers limit their applications for intravascular and implantableblood pressure sensing. Here, a high fidelity pressure transducer ispresented which is ˜10 um thick and can be embedded into any surface,including cardiovascular catheters, guide-wires, and stents. Thetransducer is micro-fabricated from various polyimides, and is bondedonto 50 um thick 316 L stainless steel foil for prototyping.

The static and dynamic characteristics of the transducer are excellent.The transducer signal has high linearity (R2>0.99), and resolution <<1mmHg which is limited only by the system noise. The operating frequencyrange is from 0 to >1 kHz, which is well over the necessary limit fordynamic cardiovascular applications, even in small animals with rapidheart rates. Additionally, theoretical analysis indicates that bothstatic and dynamic performance of the transducer can be further improvedwith optimization. Stability studies of the transducer in a pulsatileflow environment with saline and serum show little drift in transducercharacteristics over a four week period.

Exemplary embodiments of the present disclosure relate to a thin-filmsensing or actuating device. In certain embodiments, the device can beconfigured as a general sensor with broad ranging applications, asdescribed in more detail below.

Exemplary embodiments include a thin film sensor which can be integratedonto any substrate, using methods that are compatible with a range ofmaterials and sensing mechanisms. One embodiment is about 15 um, whichhas been bonded to a 50 um thick stainless steel substrate.

Exemplary embodiments include a device comprising: a substrate; and adiaphragm coupled to the substrate, wherein the diaphragm is a thin filmcapacitive transducer less than 1 mm thick. In particular embodiments,the thin film capacitive transducer is between 10 μm and 20 μm thick. Incertain embodiments, the diaphragm is coupled to the substrate via anadhesive or other bonding method. Particular embodiments furthercomprise a chamber structure between the diaphragm and the substrate.

In specific embodiments, the diaphragm is coupled to the substrate viaan adhesive; the chamber structure comprises a bonding pad around theperimeter of the chamber structure; and the chamber structure ispositioned between the diaphragm and the adhesive layer. In certainembodiments, the substrate is electrically conductive. In particularembodiments, the substrate and diaphragm are configured as a wirelessresonant pressure sensor sized for implantation in a human artery. Insome embodiments, the diaphragm is approximately 15 μm thick, and inparticular embodiments, the substrate is approximately 50 μm thick. Inparticular embodiments, the substrate is configured as an antenna. Inspecific embodiments, the device is configured to measure pressure witha linear sensitivity of approximately four percent between 0 and 400 mmHg.

In certain embodiments, the substrate and the diaphragm arebiocompatible. In particular embodiments, the device is configured as apressure sensor. In some embodiments, the device is configured as anaudio wave sensor. In specific embodiments, the device is configured asa chemical sensor. In some embodiments, the device is configured as abiological sensor. In certain embodiments, the device is configured asan optical sensor. In particular embodiments, the device is configuredas a pump. In some embodiments, the device is configured as a valve.Particular embodiments further comprise a first electrode coupled to thediaphragm and a second electrode coupled to the substrate.

Exemplary embodiments also include a method of fabricating a thin filmcapacitive transducer, the method comprising; providing a substrate;providing a diaphragm, wherein the diaphragm is between 10 μm and 20 μmthick; and coupling the diaphragm to the substrate. In certainembodiments, coupling the diaphragm to the substrate comprises usingadhesive to couple the diaphragm to the substrate. In particularembodiments, the method further comprises inserting a chamber structurebetween the diaphragm and the substrate before coupling the diaphragm tothe substrate. In specific embodiments, the diaphragm and chamberstructure are constructed using photolithography.

Described is a thin-film, diaphragm based device which can be used toperform an array of sensing and actuating operations anywhere where avery thin profile is desired, such as in millimeter, micrometer, ornanometer tight spaces. The device has a diaphragm and can operate bycapacitive, resistive, and resonant mechanisms. Due to its generalstructure, applications include: mechanical sensing and actuation,chemical-biological sensing, and optical sensing.

The device can be bonded to any substrate, allowing for deviceintegration. Additionally, the device can be constructed from flexiblematerials, which allows for applications which require flexibility,conformation to a nonflat or mobile surface, or in three dimensionalconfigurations. The device can also be fabricated as an array ofdiaphragms to measure single factors, to measure multiple factorssimultaneously, or to measure surface maps of factors. The fields ofapplication are wide ranging, from biomedical to industrial. The thinfilm sensor can be considered a platform technology for low profile MEMSsensing due to its general structure and utility.

A mechanical resonator and system for acoustic wireless interrogation ofthe resonator are also disclosed. In certain embodiments, the resonatoris micron-scale, with a resonance frequency that is strongly dependenton external pressure. Methods for interrogation of an implantedresonator include a skin piezo device which sends an impulse to theresonator. Induced resonance returns to the piezo a pressure wave at thepressure dependent frequency of the resonator. High resonancefrequencies, >1 kHz, permit hundreds of pressure samples per second,which enables a dense recreation of the blood pressure waveform.Additional factors can be measured by the sensor, including temperature,local gas—fluid environment, and local viscosity.

In one embodiment, for example, it can be used in an implantable bloodpressure sensing device where an ultra thin profile is important tosuccessful implementation. Cardiovascular problems can be addressed byone embodiment of the sensor, wherein a wireless implantable pressuresensor addresses the ubiquitous need for blood pressure monitoring andcontrol, given the many conditions which hypertension negativelyaffects. Rates of heart attack, stroke, heart failure, and cardiacarrhythmias are all significantly increased at higher blood pressurelevels. Exemplary embodiments of the device could serve as a monitoringof blood pressure for patients with a chronic cardiovascular conditionto ensure compliance with treatment and as a warning system for an acuteevent. The potential demand is large as, according to the AHA,cardiovascular disease accounts for nearly $500 billion in cost, $75billion of which is exclusive to hypertension and sequelae.

In certain embodiments, the device may comprise a sensing diaphragm thatis approximately 15 μm thick, which is bonded to a stent material (e.g.,50 μm stainless steel). Exemplary embodiments can provide a linearsensitivity of about 4% over 400 mmHg Exemplary embodiments provide gooddynamic fidelity, and have been shown to accurately measure frequenciesup to 10 kHz (and possibly higher, as higher frequencies have not beentested). In vitro studies are currently underway to characterize therobustness of the sensor over time. In vitro studies with the sensor andantenna in wireless mode are also planned in the future.

The device may be used in many applications, including for example:arrays of force/pressure sensors could be used as a tactile sensor, fordiabetic patients with nerve damage and foot/skin ulcers, or forrobotics applications. In addition, two pressure sensors spaced in atube/artery can measure fluid flow rates by the pressure drop. Incertain embodiments, the device can be used for mechanical sensing andactuation; bio-chemical sensing; optical sensing; implantableintravascular pressure monitoring; and cardio-vascular implants; andapplications in implants for hearing loss.

In a specific embodiment, the device may be configured as a pressuresensor in an inductor-capacitor (LC) resonator for a wirelessimplantable blood pressure sensor. Such a device relates to a wirelessimplantable blood pressure sensor that reduces the thickness of thetransducing element for its implementation in medium to small arteries,including the peripheral arteries. One aspect of the device replaces thethick silicon wafer onto which most pressure sensors are built with avery thin substrate or the surface of an existing device or implant.This substitution of platforms can save hundreds of micrometers ofthickness. In addition, using the shape-memory NiTi as an antenna allowsfor an antenna that can be radially compressed and self-expand during apercutaneous catheter delivery of the device.

A wireless implantable pressure sensor that addresses the ubiquitousneed for blood pressure monitoring and control and could serve as amonitoring of blood pressure (BP) for patients with a chroniccardiovascular condition to ensure compliance with treatment and as awarning system for an acute event. However, exemplary embodiments of thepressure transducer have applications beyond an implantable sensor.

With a diaphragm thickness of approximately 15 μm, the device could bebonded to the tip of a catheter for intravascular pressure sensingduring operations. Biomedical applications beyond cardiovascular includeocular pressure sensing, compartment (syndrome) sensing, and integrationinto Lab-on-Chip (LOC) systems. Industrial applications includelocations with heavy space constraints and/or need for physicalflexibility, including robotics and tire pressure systems.

A thin film diaphragm sensor is described herein with multipleapplications, including: mechanical sensing and actuation,chemical-biological sensing, and optical sensing. Exemplary embodimentsof the device are approximately 10-20 μm thick and can be bonded tovirtually any substrate. Exemplary embodiments may comprise a deflectingdiaphragm mechanism which can be used under a variety of sensing andactuating mechanisms.

Certain exemplary embodiments of the device may be configured as apressure sensor or an acoustic sensor. In the former, its thin profilecan allow for implantable endovascular blood pressure monitoring. Whencoupled with a self-expanding coil composed of shape memory metal, itcan be deployed conveniently through percutaneous catheterization andinterrogated with a small coil near the skin surface. In an acousticapplication, the device can provide for high transduction fidelitythrough the audible range.

Exemplary embodiments of the diaphragm device can be configured asclosed cells or channels or as open cells or channels. The formerconfiguration primarily serves in physical, mechanical, and resonancesensing and some forms of actuation. The latter configuration primarilyserves in permittivity based sensing for biological and chemicalfactors, and some forms of actuation.

Closed cells are critical for establishing a pressure difference betweenthe device chambers and the outside, which then allows for diaphragmdeflection. Open cells are critical for allowing biological or chemicalfactors for permeating the inter-electrode space during permittivitybased sensing. Additionally, access to the inter-electrode space isnecessary in some forms of actuation, such as in pneumatic actuation ofthe diaphragm. Modes of Operation

Exemplary embodiments of the disclosed diaphragm based device can beused in capacitive mode (two overlapping electrodes), in resistive mode(resistors on or within the diaphragm), in resonance mode (diaphragm isdriven into mechanical resonance), or as a mechanical actuator. Asdescribed more fully below:

(1) Capacitive Mode

Capacitance=ε A/z

-   -   ε—electrical permittivity of material/space between the        electrodes    -   A—Area of overlapping electrodes    -   z—gap between electrodes

Mechanisms of Capacitive Sensing

A factor that modifies any of these three properties can be sensed by acapacitive sensor.

(i) The most common sensing mechanism is by shifting the electrode gap(Δz) by diaphragm deflection. In this mode, force, pressure, andacoustic signals are typical measured which are directly sensed.Numerous other factors can be indirectly sensed by a deflectingdiaphragm. For instance, flow can also be measured with two pressuresensors in series. Additionally, biochemical factors and analytes can besensed if a swelling smart material, for instance a receptor conjugatedhydrogel, fills the electrode gap. Also, optical sensing can be achievedin a Golay cell configuration, described later.

(ii) Changing the permittivity (Δε) is an additional sensing mechanism.Typically, a permeable material fills the space between electrodes andabsorbs the factor or analyte. Absorption alters the permittivity andchanges capacitance. Humidity and pH are commonly sensed by thismechanism, but an analyte specific material such as a receptorconjugated polymer (e.g., hydrogel) can allow for specific biochemicalanalytes to be sensed by this method. Additionally, a swelling hydrogelmay combine the effects of permittivity shifts and diaphragm deflection.

(iii) Changing the area of overlapping electrodes (ΔA) is anothersensing mechanism of capacitors with certain moving parts. Shear forcesand acceleration by comb-drives or other arrangements are measured.However, since our capacitive sensor has fixed borders around thediaphragm, this mechanism does not apply.

(2) Resistive Mode

The most common pressure sensor is a deflecting diaphragm with a bridgeof resistive sensors, either thin metal films or semiconductors.Deflection strains the diaphragm and its associated resistors, whichthen modifies their resistance.

In this mode, applications would likely be limited to force or pressuresensing, and their derivatives such as flow or acoustic sensing.

(3) Resonance Mode

The basic mechanism is that the diaphragm is driven into mechanicalresonance and this resonance frequency is monitored. A factor whichmodifies this resonance frequency can then be detected.

A primary application of this sensing mechanism is for biological orchemical sensing. In this mode, the exposed surface of the diaphragm isconjugated with a receptor for the measured factor. Depending on itsconfiguration, the diaphragm can be driven into resonance by variousmeans, including electrostatically (if it contains parallel electrodes),thermally, or an applied pressure via an acoustic signal or a pop-test(a step drop in pressure, which induces resonance in the diaphragm). Theresonance frequency can be monitored electrically by various methodswhich depend on whether the diaphragm device is acting as a variablecapacitor or a variable resistor. When the biological or chemical factorbinds the receptor, it mass loads the diaphragm and thereby shifts itsresonance frequency.

(4) Mechanical Actuator

Whereas the sensing diaphragm moves in response to a signal, thediaphragm can alternatively be driven into movement to achieve amechanical goal. Methods to induce mechanical actuation includepneumatic, electrostatic, thermal, among others. Most applications of athin film mechanical actuator will likely lie in microfluidics devices,where the actuator can serve as a valve, a pump or other pressurizingdevice.

Sensing Types and Possible End Applications

Exemplary embodiments of the disclosed diaphragm based device can beused to achieve mechanical and physical sensing, mechanical actuation,biological and chemical sensing, and optical sensing, among others.

(1) Mechanical and Physical Sensing

The diaphragm device can operate as a force sensor under numerousconfigurations and conditions where a thin profile or flexibility isdesired.

(i) Biomedical applications of force or pressure sensors includecardiovascular blood pressure or flow sensing (e.g., hypertension, heartfailure), ocular pressure sensing (e.g., glaucoma), pulmonary pressuresensing (e.g., chronic obstructive pulmonary disease), pleural cavitypressure sensing (e.g., pneumothorax), urinary pressure sensing (e.g.,incontinence), gastrointestinal pressure sensing (e.g., incontinence),peritoneal cavity pressure sensing (e.g., ascites), cerebro-spinal fluidpressure sensing (e.g., hydrocephalus), muscular pressure sensing (e.g.,compartment syndrome), orthopedic pressure sensing (e.g., joint, disc,and/or implant pressures), podiatric pressure sensing (e.g., fordiabetic ulcers) among others.

One particular use of high value would be on a catheter tip forintravascular blood pressure sensing or for urological sensing.Currently, in the hospital wards, fluid filled catheters transmitpressures from inside the body to an external pressure sensor. Thisarrangement has significant sensitivity and drift errors, in addition toartifacts such as the catheter whip effect, which reports artificiallyhigh spikes in pressure when the fluid filled catheter moves. Siliconmicrosensors do exist, but are very expensive (>$1 k) and sterilizationfor re-use between patients is not common for safety reasons. Aninexpensive, thin, flexible sensor which could be positioned at the tipof a disposable catheter could considerably improve pressure sensingaccuracy. Additionally, a very thin profile would allow for measuringpressures in tighter spaces than are currently possible.

An additional application of high value for a thin pressure sensor is inimplantable blood pressure sensing devices. Currently, silicon basedmicrosensors are built onto silicon or silica chips which are at leastseveral hundred microns in thickness. This thickness precludesapplications in all but the largest arteries, since most medium andsmall arteries, such as the coronaries and peripheral arteries, are <4mm in internal diameter. An implantable blood pressure sensing devicehas value in direct, continuous, and chronic monitoring of hypertensionand heart failure, and can additionally serve as warning system foracute cardiovascular events. Such a device could be constructed as aninductor-capacitor (LC) system, with the thin pressure transducer incapacitive mode. It could also be constructed alternatively, where thetransducer operates in either resistive or capacitive mode.

(ii) Capacitive microphones are very common for transducing audiosignals. One biomedical application of a very thin audio transducer isin an unobtrustive hearing device, such as an inner ear implant, acochlear implant, or hearing aid. The thinness is of particularrelevance, as the tympanic membrane is ˜50 um thick. Additionally, thesensing range is not necessarily limited to the audible range, however,and applications may include the sub-audible and ultrasound ranges.

(iii) Industrial applications for force and pressure sensing includeautomotive (e.g., tire pressure sensing, force sensors for monitoringshock, misalignment), machines and robotics (e.g., monitoring shock,misalignment), among others.

(iv) Robotics applications include artificial skin for tactile sensing.An array of diaphragms would allow for sensing a two dimensional surfacemap. Such an artificial skin could be used in a sensing skin forartificial intelligence robotics or in a prosthetic for sensory loss inhumans.

(2) Mechanical Actuation

Most applications of a thin film mechanical actuator will likely lie inmicrofluidics devices, where the actuator can serve as a valve, a pumpor other pressurizing device. As a valve, one or multiple diaphragms cansituated as walls of a micro-channel. The diaphragm can be drivenoutward or inward for either by an electrostatic signal across the twoelectrodes or by a pneumatic signal from within the inter-electrodespace. The valve state will be closed when the diaphragm is driven outand contacts the opposing wall, thereby occluding the channel. The valvestate will be open when the diaphragm is driven in.

As a pump, the diaphragm can be driven to induce pressure to drive flowin an adjacent chamber or channel. Upstream the pump can be a one-wayvalve which blocks backwards flow, such that the pump only drivesforward flow.

The diaphragm device could also operate as a miniature capacitivespeaker, either in the sub-audible, audible, or ultrasound range. Thismode of operation, the diaphragm would likely be drivenelectrostatically. As with the audio transducer operating in anunobtrusive hearing device, a miniature speaker could also be used insuch a device for amplification of the audio signal.

(3) Biological and Chemical Sensing

Biological and chemical sensing in tight spaces has biomedicalapplications, among others in high technology. Possible transductionmechanisms include resonance or capacitive modes. An array of diaphragmscould allow for monitoring of multiple markers.

This transducer could be used in an implantable device for monitoringbiomarkers, for monitoring the status of either chronic disease orcancer. If configured to give surface map data, the device could be usedas an artificial tasting or smelling device (smart tongue or smartnose).

(4) Optical Sensing

Indirect optical sensing can be achieved in a Golay cell configuration,whereby an air chamber with an optical filter sits atop the deflectingdiaphragm. The optical signal enters the top chamber, changes itstemperature, which induces expansion or contraction of the chambervolume, and thereby changes the applied pressure to the diaphragm of thecapacitive sensor below.

If the sensor is configured as an array of frequency specific opticaltransducers, an optical camera can be achieved for imaging applications.A specific biomedical application of such an optical camera includes aretinal implant for restoring vision. The thin, flexible nature of thesensor confers a particular advantage for conforming to the curvedtopography of the eye.

In the following, the term “coupled” is defined as connected, althoughnot necessarily directly, and not necessarily mechanically.

The use of the word “a” or “an” when used in conjunction with the term“comprising” in the claims and/or the specification may mean “one,” butit is also consistent with the meaning of “one or more” or “at leastone.” The terms “about”, “approximately” or “substantially” means, ingeneral, the stated value plus or minus 5%. The use of the term “or” inthe claims is used to mean “and/or” unless explicitly indicated to referto alternatives only or the alternative are mutually exclusive, althoughthe disclosure supports a definition that refers to only alternativesand “and/or.”

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a method ordevice that “comprises,” “has,” “includes” or “contains” one or moresteps or elements, possesses those one or more steps or elements, but isnot limited to possessing only those one or more elements. Likewise, astep of a method or an element of a device that “comprises,” “has,”“includes” or “contains” one or more features, possesses those one ormore features, but is not limited to possessing only those one or morefeatures. Furthermore, a device or structure that is configured in acertain way is configured in at least that way, but may also beconfigured in ways that are not listed.

Other objects, features and advantages of the present invention willbecome apparent from the following detailed description. It should beunderstood, however, that the detailed description and the specificexamples, while indicating specific embodiments of the invention, aregiven by way of illustration only, since various changes andmodifications within the spirit and scope of the invention will beapparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings form part of the present specification and areincluded to further demonstrate certain aspects of the presentdisclosure. The invention may be better understood by reference to oneof these drawings in combination with the detailed description ofspecific embodiments presented herein.

The patent or application file contains at least one drawing executed incolor. Copies of this patent or patent application publication withcolor drawing(s) will be provided by the Office upon request and paymentof the necessary fee.

FIG. 1 shows an exploded view of one embodiment of a device according tothe present disclosure.

FIG. 2 shows a section view of the embodiment of FIG. 1.

FIG. 3 shows a graph of capacitance versus pressure for one embodimentof a device according to the present disclosure.

FIGS. 4-9 illustrate properties of the embodiment of FIG. 3 as measuredover period of several days.

FIGS. 10-11 illustrate measurements of the embodiment of FIG. 3 ofdynamic signals from inside a flow loop with pulsatile pressure.

FIG. 12 shows a schematic of one embodiment of a device configured as anaudio sensor.

FIG. 13 shows data recorded with the embodiment of FIG. 16.

FIGS. 14-25 show circuits and data for a specific embodiment for insolepressure measurement.

FIGS. 26-28 illustrate data for exemplary embodiments of four sensorsaccording to the present disclosure over one month in saline underpulsatile pressure.

FIGS. 29-32 contain regressions and drift of parameters over the onemonth period for the data illustrated in FIGS. 26-28.

FIGS. 33-39 contain data from one sensor which addresses the source ofdrift in the parameters for the data illustrated in FIGS. 29-32.

FIG. 40 illustrates a schematic of an exemplary embodiment of aresonator according to the present disclosure.

FIG. 41 illustrates resonance frequency signals at different pressuresfor exemplary embodiments of devices according to the presentdisclosure.

FIGS. 42-43 illustrate data showing the pressure dependence of diaphragmresonance frequency.

FIGS. 44-45 illustrate schematics of exemplary embodiments of resonatordevices anchored to a structure according to the present disclosure.

FIG. 46 illustrates a schematic of acoustic interrogation of anexemplary embodiment of a mechanical resonator according to the presentdisclosure.

FIG. 47 illustrates schematics for wireless sensing modalities forexemplary embodiments of implantable sensors according to the presentdisclosure.

FIG. 48 illustrates a coordinate system and a schematic of an exemplaryembodiment of an analytical model according to the present disclosure.

FIGS. 49-51 illustrate an experimental setup used to obtain resultspreviously shown in FIGS. 41-43.

FIGS. 52-53 illustrate frequency versus pressure data in the audiblerange obtained from exemplary embodiments of resonators according to thepresent disclosure.

FIGS. 54-55 illustrate data showing the penetration of audible acousticwaves in soft tissue.

FIG. 56 illustrates the level of acoustic energy that can be deliveredto a resonator for different materials according to the presentdisclosure.

FIG. 57 illustrates the reflected pressure ratio and reflected powerratio for soft tissue in combination for different materials.

FIGS. 58-60 illustrate a schematic of an experimental set up forultrasonic measurements and data obtained from the experiment.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring initially to FIGS. 1-2, an exemplary embodiment of a device100 configured as a thin film sensor comprises a diaphragm 110, achamber structure 120, an adhesive 130 and a substrate 140. In theembodiment shown, diaphragm 110 is configured as a thin film diaphragmtransducer between 10 μm and 20 μm thick and is bonded to substrate 140via adhesive 130. In particular embodiments, diaphragm 110 isapproximately 15 μm thick and substrate 140 is approximately 50 μmthick. In the present disclosure, the thickness of a material ismeasured across the primary plane of the material (i.e. the minimumdimension for a given layer of material, as would be measured in avertical direction in the configuration shown in FIG. 2).

In the illustrated embodiment, chamber structure 120 comprises a bondingpad 125 around its perimeter and chamber structure 120 is positionedbetween diaphragm 110 and substrate 140. In exemplary embodiments ofdevice 100, substrate 140 can be electrically conductive, and in certainembodiments can be configured as an antenna.

Exemplary embodiments of device 100 may be fabricated by constructing athin sensing film, which comprises of an array of diaphragms 110enclosed by bonding pads 125. In certain embodiments, to construct thesensing film, multiple layers of photolithography with variouspolyimides can be performed on a carrier substrate. The diaphragm can bedefined in one step, the chamber walls can be defined in a second step,and a thin adhesive film applied in a third step. The sensing film canthen be released from the carrier.

In exemplary fabrication techniques, the sensing film can then be bondedto the substrate of choice. In certain embodiments, the thin adhesivecan be deposited onto a conductive substrate. If the substrate is notinherently conductive, a thin conductive film may be deposited toprovide a bottom electrode of the diaphragm sensor. The sensing film canthen be bonded to the substrate under pressure and temperature.

In certain embodiments, the final fabrication step is to sputter anelectrode and bond lead wires. For example, a thin conductive film canbe deposited on top of the sensing film to define the top electrode ofthe diaphragm sensor. Lead wires can then be bonded onto the top andbottom electrodes.

In certain embodiments of the sensor, the sensing film (e.g. diaphragm110) is 10-15 μm thick and substrate 140 is 50 μm thick stainless steel.In certain embodiments, diaphragms 110 form a sensing film that is 3mm×10 mm, but it can be of arbitrary size to suit the application.

In certain embodiments, substrate 140 may be formed by polymersprocessing techniques. Other microfabrication techniques could produce asimilarly-structured device composed of other materials, includingtraditional microfabrication ceramics such as silicon, silica, quartz,silicon nitrides, other nitrides, other oxides, and other insulating orsemiconducting materials.

During operation of device 100, deflection of diaphragm 110 toward andaway from substrate 140 can be measured by changes in electricalproperties and correlated to environmental conditions or parametersaffecting device 100. For example, in certain embodiments, thecapacitance of device 100 (measured between diaphragm 110 and substrate140) can be correlated to pressure. Referring now to FIG. 3, one exampleillustrates a substantially linear relationship between the measuredcapacitance (in pF) versus the pressure on diaphragm 110 (measured inmmHg). FIGS. 4-9 illustrate other properties of the embodiment of FIG. 3as measured over period of several days. FIGS. 10 and 11 illustratemeasurements of the embodiment of FIG. 3 of dynamic signals from insidea flow loop with pulsatile pressure. FIG. 10 illustrates waveforms fromdevice 100 and a reference sensor. As illustrated, the averagedifference is approximately 1 mm Hg.

Referring now to FIGS. 12 and 13, a schematic of device 100 (andresulting data) are shown for an embodiment configured as an audiosensor. In this embodiment, device 100 senses an audio wave 150, whichcauses deflection of diaphragm 110 (not labeled in FIG. 6 for purposesof clarity; see FIGS. 1 and 2 for view depicting diaphragm 110).Diaphragm 110 deflections cause a change in the measuredcapacitance/voltage across device 100, which can be viewed as a waveformon display 160.

In the graph shown in FIG. 13, audio frequencies were recorded with highfidelity up to 10 kHz, indicating certain embodiments of device 100 maybe suitable for use for hearing aid implants. In addition, the abilityto record frequencies up to 10 kHz also indicate the potential utilityof device 100 in cardiovascular applications due to the ability tofaithfully record high frequency information in the pressure waveform.

Device 100 can be used in many different applications. For example,device 100 can be configured for use as a sensor, including a pressure,acoustic, force or flow sensor. Device 100 may also be configured as amechanical actuating device, including for example an electrostatically(or pneumatically)-driven membrane that can be used as a pump or valvein microfluidics applications. For example, in a valve configuration,diaphragm 110 can be deflected outward (e.g. away from substrate 140) toocclude flow and toward substrate 140 to allow flow to pass overdiaphragm 110.

In still other embodiments, device 100 can be configured a capacitivemicrophone, including for example configuration a hearing aid.

In certain embodiments, device 100 can be configured as a chemical orbiological sensor. For example, chamber structure 120 can be configuredas a polymer or hydrogel with selective absorption that can swell anddeflect diaphragm 110 in the presence of certain analytes.

In particular embodiments, device 100 may also be used for detectingchemical or biological analytes by mass loading of the sensingdiaphragm, which changes its resonance frequency. The sensing diaphragmcan have analyte receptors bound to its surface and the resonancefrequency of the sensing diaphragm can be monitored by actuating device100 electrostatically or thermally. Detection of the analyte occurs byrecording the shift in resonant frequency of the diaphragm.

In specific embodiments, device 100 may be configured for indirectsensing by principles similar to those used in a Golay cell. Forexample, chamber structure 120 may be filled with a gas that expandswith increased temperature and causes deflection of diaphragm 110. Inparticular embodiments, diaphragm 110 may be coated with a bandpassfilter to provide for specific detection of light wavelengths or color.Such configurations could be used in imaging or retinal implantapplications.

In certain embodiments, device 100 can be configured as a thin-filmpressure sensor in an inductor-capacitor (LC) resonator for a wirelessimplantable blood pressure sensor. In particular embodiments, device 100can operate by capacitive, resistive, and resonant mechanisms. Inexemplary embodiments, device 100 can sense a broad range of factors,individually and multiple simultaneously. Device 100 can be configuredas an electrical inductor-capacitor (LC) resonator that measurespressure by a thin film capacitive transducer that resonates with astent-like antenna.

In exemplary embodiments, the thin active region of the sensor isdecoupled from a thick inactive substrate. Certain embodiments canincorporate the use of a shape-memory NiTi as an antenna forpercutaneous catheter delivery of the device. In certain embodiments,movements in local pressure change the transducer capacitance and thusshift the resonance frequency. In particular embodiments, the resonancefrequency can be monitored externally by magnetic coupling to determineintravascular pressure.

In specific embodiments, the sensor can be bonded to a thin metallicsubstrate and coupled to a flexible NiTi stent-antenna (inductor), andthe diaphragm sensor and inductive antenna form an electricalinductor-capacitor (LC) resonator.

In certain exemplary embodiments, device 100 has a thin profile, iswireless, biocompatible, implantable, and allows for intravascularimplantation for blood pressure sensing. In particular embodiments,device 100 can be fabricated with biocompatible materials, is flexibleand due to thin profile allows for 3-D conformations of sensor in vivo,allows for implementation in medium to small arteries, including theperipheral arteries.

In particular embodiments, device 100 can be bonded to virtually anysubstrate, and be integrated or embedded into various devices. The thinand flexible profile of device 100 is suitable for implantation intoconstrained spaces which were previously inaccessible for sensors.

The replacement of a thick silicon wafer onto which most pressuresensors are built with a very thin substrate (or the surface of anexisting device or implant, including e.g. a stent) can save hundreds ofmicrometers of thickness which can be critical in particularapplications. For example, one embodiment enables the development of awireless resonant pressure sensor which is suitable for implantation ina large, medium, or small sized artery. As described in the literaturereviews on endovascular blood pressure sensing devices and on pressuretransducers, transducer size has been a limiting factor in thedevelopment of small implantable devices.

As described previously, exemplary embodiments of the present disclosuresubstitute the platform for the sensing diaphragm to reduce sensorthickness. Commercially available pressure sensors use silicon wafer assubstrates with a thickness of about 500 μm, most of which can beeliminated by integrating the sensing element onto a robust surface ofthe device.

Test Data

FIGS. 26-28 provide raw data on four sensors over one month in salineunder pulsatile pressure. The data includes all tracked parameters, andthe sensors had an initial two week immersion period in saline to allowparameter values to settle. Those values were then measured two timesper week.

FIGS. 29-32 contain regressions and drift of parameters over the onemonth period. A graph at the end shows average drift in each parameter.

FIGS. 33-39 contain data from one sensor which addresses the source ofdrift in the parameters. Pressure was increased to 400 mmHg and pressuresensitivity curves were recorded; this was repeated for ten consecutivecycles. Some drift in sensor parameters are noted (for instance, 0.15%increase in baseline capacitance). The sensor was left alone for atwelve hour break, and then ten more cycles were performed. For almostall of the parameters, after the twelve hour break, the parameter valuereturned to the original value from day one, indicating that the driftin parameters was not permanent (e.g., a hysteresis effect which can beaddressed during development and commercial design).

Design and fabrication of exemplary embodiments requires detailedknowledge and synthesis of multiple fields including microelectronics,microfabrication, cardiovascular medicine, and biomaterials.Additionally, silicon wafers are the epicenter of the microelectronicsand microfabrication fields; departing from this fabrication orthodoxyis difficult.

Embodiments of the current invention include a class of resonant sensorswhich can be used in a shoe insole for monitoring foot pressures. Thegeneral sensor is a resistor-inductor-capacitor (RLC) resonant circuit,which allows for either capacitive sensing or resistive sensing. FIG. 14shows circuit schematics of these two possible configurations. In bothcases, an external device with a small coil and a radio link (e.g.,Bluetooth), such as a clip on the outer shoe, an anklet, or a waistbelt, can interrogate the sensor and transmit the pressure signals to asmart device, computer, or wireless network.

In the capacitive design, a planar conductive coil is electricallyconnected to a capacitive pressure transducer to form an RLC tank, whichis then embedded into an insole. The resonance frequency of the tankdepends on the applied pressure. The sensor can be interrogated by anexternal coil which sweeps across a specified frequency range to monitorshifts in the resonance frequency.

In the resistive design, a planar conductive coil is electricallyconnected to a capacitor and a resistive transducer to form an RLC tank,which is then embedded into an insole. In this case, the resonancefrequency of the tank is fixed, but the quality of resonance (qualityfactor Q) depends on the applied pressure. The sensor can beinterrogated by an external coil at a fixed frequency by monitoring thestrength of the magnetically coupled signal.

The capacitive design of an RLC sensor has been enabled. Referring backnow to FIG. 15, a prototype insole is shown with a thin film capacitivetransducer and an embedded 2-turn coil. The prototype has a strong andlinear pressure sensitivity (40 kHz/PSI; R2=0.993). Further experimentaldata are attached in an appendix. A video of the sensor in operationwill be sent electronically. The particular type of capacitivetransducer is non-essential to the invention. A variety of thintransducers could easily be used, from capacitive microsensors to customcapacitive sensors made from a sandwich of thin metal foil with acompressible dielectric in the middle.

FIGS. 17-19 provide pressure data for various embodiments, while FIG. 20provides a schematic showing different features of existing systems andan embodiment of the present disclosure using a magnetic coupling and aradio link.

FIGS. 21-25 provide data on a wireless insole reading range according toexemplary embodiments of the present disclosure. For all sensors, datawas acquired with a non-optimized sensor and a non-optimizedinterrogation system. The impedance analyzer operated at 0.5V across theinterrogating coil (instrument limit). Industry RFID interrogatorsfrequently use >10V to increase sensitivity, and frequently haveinterrogation distances of >1 m for resonant tags approximately 1 cm.

It is understood that the above-described devices and methods are merelynon-limiting examples of embodiments of the devices and methodsdisclosed herein.

Exemplary embodiments of the present disclosure include resonators thatoperate in the audible acoustic range. Existing systems typicallystipulate stimulation in the ultrasound range.

Bandwidth of the acoustic transmitter and/or receiver in exemplaryembodiments of the present disclosure is much lower than standardultrasound crystals. In certain embodiments, a unique probe may bedeveloped for this application in the 1-20 kHz range.

Mechanical resonators are most sensitive to gauge pressure, and only tothe first several hundred mmHg, after which sensitivity dropsconsiderably. Therefore, it is not possible simply to use or test anycommercially available pressure sensor with a micromachined diaphragm,which have chambers underneath which are frequently hermetically sealedunder vacuum. In the case of vacuum sealed, commercially availablepressure sensors, the gauge pressure across the diaphragm at thephysiological range is >800 mmHg, which offers negligible pressuresensitivity if used as a mechanical resonator.

An exemplary embodiment of a prototype resonator is square polyimidediaphragm (500 um long, 5 um thick) over a closed air chamber, as shownin FIG. 40. In this embodiment, a square diaphragm made of polyimideover an air chamber is bonded to stainless steel substrate.

Modification of the standard equation for determining the resonancefrequency of such a diaphragm (Roark) yields the following expressionfor resonance frequency with a strong pressure dependence

${F(p)} = {\frac{36}{2\pi}\sqrt{\frac{Dg}{a^{4} \cdot \left( {w + p} \right)}}}$

where

$D = \frac{{Et}^{3}}{12\left( {1 - v^{2}} \right)}$

is the flexural rigidity of the diaphragm, v is the poisson ratio of thediaphragm material, E is the elastic modulus of the diaphragm material,t is the diaphragm thickness, a is the square diaphragm length, g is thegravitational constant, w is the weight of the diaphragm per unit area,and p is externally applied pressure (gauge pressure across thediaphragm).

Experimental testing shows good agreement with the theory. An impulsetest was applied to the prototype diaphragms at various pressures toinduce resonance. FIG. 41 clearly shows the strong pressure dependenceof the resonance on local pressure. FIGS. 42 and 43 show that theexperimental data matches the theory well. Response of the mechanicalresonator to an impulse response is shown at different pressures.Increasing pressure reduces the resonance frequency. There is a goodmatch between experimental vs predicted resonance frequency at variouspressures, for a square polyimide diaphragm 500 um long and 5 um thick.

Further theoretical analysis shows that ceramic resonators should giveneven better pressure responses, due to their rigidity. Additionally, theoutstanding mechanical stability of ceramics, particularlymonocrystalline ceramics of silicon and SiO₂ (quartz), should lendexcellent robustness and long term sensing stability.

FIGS. 44 and 45 illustrate variations of a conceived ceramic resonator,anchored to a stent or stent-like structure. In FIG. 44, the resonatoris bonded to the stent surface, while in FIG. 45 the resonator isembedded into the stent.

Once percutaneously implanted, the resonator can be interrogatedwirelessly by an acoustic impulse test. FIG. 46 illustrates how a piezodevice at the skin surface can send a pulse to the resonator, inducevibration, and read the frequency of the vibration. In section 1 of FIG.46, the piezo sends an impulse, either a square wave or a sine wave nearthe resonance frequency of the resonator. In section 2, the impulsestimulates vibration of the resonator, which produces a pressure wavewith an oscillating decay at its resonance frequency. The piezo switchesto listen mode, or a second receiving piezo is used, to record theresonator pressure wave.

If the resonance frequency of the resonator is sufficiently high (>1kHz), >>100 samples of blood pressure samples can be taken during thepressure wave cycle. This should allow for a dense recreation of theblood pressure waveform.

In the past several decades, many wireless sensing platforms have beendeveloped which utilize a radio link to transmit the sensed data.Currently, with small Bluetooth-like radio links and smart devices,these platforms are still in full force. There is a miniaturizationlimit, however, due the numerous components such as power sources,circuitry, and antennas. Resonance based systems offer an alternativefor wireless sensing, because resonators are typically very simplestructures, can be made small, and efficiently receive and transmitenergy within a certain frequency range. FIG. 47 compares these wirelesssensing modalities for implantable sensors, and optical methods couldalso be included in this comparison. In wireless modalities forimplantable sensors, conventional wireless systems are bulky, with manycomponents. Resonant systems have fewer components, no powerrequirements, and can be interrogated magnetically or acoustically

While well known in the physics, mechanics, and electrical literaturesfor over a century, resonance based sensing systems have become moreintensively investigated since the 1990s, with a particular focus onelectrical resonators. These electrical resonators require only acapacitive sensor and a coil to operate, and can be interrogatedmagnetically. Mechanical resonators, however, have not been intensivelyinvestigated for stand-alone sensing purposes.

The scientific literature is full of discussion of electrical andmechanical resonance and resonators. The engineering literature hasseveral well recognized instances, the most prominent one being theclass of resonant pressure sensors in silicon microsensors.Incidentally, these resonant pressure sensors are known to havesensitivity and stability at least an order of magnitude great thanpiezoresistive and capacitive sensors. In this class, a micro-beam lieson a deflecting diaphragm and is induced into resonance. Pressuredeflects the diaphragm and changes the strain on the beam, whoseresonance frequency then shifts. This shift is monitored bypiezoresistors on the beam, which are then processed by circuitry on ornear the transducer chip. An important aspect is that most declared“resonant sensors” operate similarly to this class of sensors and arenot stand-alone, passive resonant sensors which can be wirelesslyinterrogated.

Significant intellectual property exists on the class of stand-alone,passive mechanical resonators. Included is an appendix table withexamples of differences between the disclosed invention and the relevantpatents. The significant point is that the inventions are largelyundeveloped and, without a known exception, utilize a very differentacoustic frequency range. The work in patents is done predominantly inthe medical ultrasound range (MHz), whereas the disclosed invention hereoperates in the audible range (<20 kHz). Additionally, and related tothis distinction, the method of interrogation of the patented inventionsis frequently different from that of this disclosed invention.

Exemplary embodiments of the present disclosure provide numerousnon-obvious advantages over existing systems. For example, the analyticsolutions for resonance frequency of diaphragms and beams do not containexplicit pressure terms, and thus the pressure dependence is notobvious. Minor modifications of the formulas readily yield pressuredependence, but the insight to make them must first be had. In addition,the mechanism of sensing is fundamentally different from that of mostsilicon-based resonant pressure sensors. Most silicon-based resonantpressure sensors focus on inducing a pressure dependent strain on aresonating beam. This is typically done by deflecting the mechanicalbase on which the beam lies, or by deflecting another mechanical memberonto the beam. IE, the resonance frequency of the sensing element is notdirectly shifted by local pressure. In our case, resonance frequency ofour disclosed invention is directly shifted by local pressure.

Furthermore, the acoustic frequency range of the disclosed invention isfully audible (<20 kHz) rather than very high ultrasound (MHz). Thelargely undeveloped inventions covered in the scientific and patentliterature typically operate in the medical ultrasound frequency range,which is 2 to 4 orders of magnitude higher than that of the disclosedinvention here. The interrogation systems for this prior art aretypically standard medical ultrasound probes, which limits the frequencyrange of the implantable sensors. Additionally, embodiments of thedisclosed invention are only sensitive to low levels (several 100 mmHg)of gauge pressure across the diaphragm. That is, silicon transducerswith diaphragms over vacuum sealed chambers (most of them) will notexhibit significant pressure dependence of their resonance frequency; atsensing levels, gauge pressure across the diaphragm is >800 mmHg Forexample, the theory of the disclosed invention must be understood, andadditionally, an off the shelf transducer cannot be used to empiricallyvalidate that theory.

To date, numerous systems exist for attempting to measure intravascularblood pressure, but all have significant limitations. For implantabledevices, miniaturization and powering are the key limitations. Fornoninvasive devices (optical, tonometry), blood pressure waveforms caneasily be generated, but scaling them with accurate systolic anddiastolic values has been a persistent challenge.

Embodiments of the disclosed invention offer a solution, by providingsimple passive sensor which can be anchored onto stent-like structureand be acoustically interrogated. The sensor can be made extremely small(low micron), and can be made of extremely stable ceramics (SiO2) toconfer long term sensing stability. Additionally, the device has strongpressure sensitivity, enabling tenths of mmHg to be accurately measured

In one example, a mechanical resonator can be configured as animplantable blood pressure sensor capable of measuring varying low,medium, and high pressure ranges and operating in one of the wirelessmodalities shown in FIG. 47.

FIG. 48(a) illustrates a coordinate system, while FIG. 48(b) provides anillustration for an analytical model. In this example, 2 a=length ofsquare diaphragm; t=thickness; d=deflection.

Analytic Expression for Resonance Frequency

In an air environment, the analytical solution for the natural resonancefrequency of a square plate with damped edges

$\begin{matrix}{f_{0} = {\frac{36}{2\pi}\sqrt{\left( \frac{D}{a^{4}} \right) \cdot \left( \frac{1}{q} \right)}}} & \left( {11a} \right)\end{matrix}$

where

$D = \frac{{Et}^{3}}{12\left( {1 - v^{2}} \right)}$

Is the flexural rigidity of the diaphragm, a is the square diaphragmlength, and q is the load on the diaphragm including its weight per unitarea and applied pressure. Here, the spring constant of the diaphragm is

$K = {\sqrt{\left( \frac{324 \cdot D}{\pi^{2}a^{4}} \right)}.}$

FIGS. 49-51 show an experimental setup used to obtain results previouslyshown in FIGS. 41-43, and FIGS. 52-53 illustrate frequency versuspressure data obtained prototyping and development in the audible range.

FIGS. 54-55 illustrate the high penetration of audible acoustic waves insoft tissue. FIG. 54 demonstrates ultrasound attenuation occursexponentially with penetration depth, and increases with increasedfrequency. The curves show the relative intensity of ultrasound at aparticular frequency as a function of penetration depth in a medium withan attenuation coefficient of (0.5 db/cm)/MHz. The total distancetraveled by the ultrasound pulse and echo is twice the penetrationdepth.

FIG. 55 demonstrates an attenuation function of a phantom measured usingthe pulse-echo substitution method. As shown, in the frequency range of1.2 to 4.4 MHz, the least squares line is y=0.0767+0.692 x. The linearcorrelation coefficient is 0.9996. FIG. 56 is a chart showing the highlevel of acoustic energy that can be delivered to the resonator fordifferent materials. FIG. 57 shows the reflected pressure ratio andreflected power ratio for soft tissue in combination with glass,stainless steel, and air, where:

${{Reflected}\mspace{14mu} {Pressure}} = \frac{Z_{2} - Z_{1}}{Z_{2} + Z_{1}}$${{Reflected}\mspace{14mu} {{Intensity}\left( \frac{Power}{Area} \right)}} = \left( {{Reflected}\mspace{14mu} {Pressure}} \right)^{2}$

FIGS. 58-60 illustrate a schematic of an experimental set up forultrasonic measurements and data obtained from the experiment, asdisclosed in M. W. Borner et. al., Sensors and Actuators A 46-47 (1995)62-65. FIG. 58 illustrates the schematic for the measurements, whileFIG. 59 illustrates amplitude versus time data for (a) a micromembranessupported by a nickel honeycomb structure; (b) a membrane without themicrostructure; and (c) the honeycomb structure alone. As shown in thefigure, the echo from the micromembranes consists of two parts, with thefirst representing the initial signal and the second part attributed tovibrations of the membranes. As shown, echoes from the membrane ormicrostructure alone do not show the second part of the signal. FIG. 60shows a Fourier transform of the signal, where the resonance frequencyof the micromembranes can be seen.

As demonstrated herein, resonators used as implantable sensors providenumerous advantages, including no on-site power source or circuitryrequirements, very small, and a robust design. Mechanical resonatorsprovide numerous advantages (e.g. over electrical resonators), includingthe fact that non-electrical, extremely small mechanical resonatorsensors can be implanted. In addition, mechanical resonators provideincredible sensitivity, given how sensitive mechanical resonance is toexternal pressure, and can be tailored to specific pressure ranges.Mechanical resonators theoretically excellent readout range given howwell acoustic signals travel through the body. In addition, mechanicalresonators have much more sensing stability over time, again becauseelectronics are not necessary, and an elastic ceramic (quartz, glass,silicon, whatever) will not plastically deform over time. Furthermore,mechanical resonators provide for pulsewave recreation because theresonance frequency is high enough to permit dozens of samples persecond in an unoptimized sensor, and possibly hundreds per second in anoptimized sensor.

In addition, mechanical resonators provide audible acoustic (<10 kHz)interrogation rather than ultrasound and inexpensive piezoelectrics canbe used instead of expensive ultrasound crystals and devices. Mechanicalresonators provide much simpler readout electronics with inexpensivepiezoelctrics and without frequency sweeps utilizing a simple, one-timeacoustic pulse and then listen for the resonance echo. Furthermore,mechanical resonators can be configured with a very small size (μm rangein any dimension). In certain embodiments, mechanical resonators can besized small enough to be coupled to a stent and/or for percutaneousdelivery to implantation size.

All of the apparatus, devices, systems and/or methods disclosed andclaimed herein can be made and executed without undue experimentation inlight of the present disclosure. While the devices, systems and methodsof this invention have been described in terms of particularembodiments, it will be apparent to those of skill in the art thatvariations may be applied to the devices, systems and/or methods in thesteps or in the sequence of steps of the method described herein withoutdeparting from the concept, spirit and scope of the invention. All suchsimilar substitutes and modifications apparent to those skilled in theart are deemed to be within the spirit, scope and concept of theinvention as defined by the appended claims.

REFERENCES

The contents of the following references are incorporated by referenceherein:

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1. A device comprising: a substrate; and a diaphragm coupled to thesubstrate, wherein the diaphragm is a thin film capacitive transducerless than 1 mm thick.
 2. The device of claim 1 wherein the thin filmcapacitive transducer is between 10 μm and 20 μm thick.
 3. The device ofclaim 1 wherein the diaphragm is coupled to the substrate via anadhesive or other bonding method.
 4. The device of claim 1 furthercomprising a chamber structure between the diaphragm and the substrate.5. The device of claim 4 wherein: the diaphragm is coupled to thesubstrate via an adhesive; the chamber structure comprises a bonding padaround the perimeter of the chamber structure; and the chamber structureis positioned between the diaphragm and the adhesive layer.
 6. Thedevice of claim 1 wherein the substrate is electrically conductive. 7.The device of claim 1 wherein the substrate and diaphragm are configuredas a wireless resonant pressure sensor sized for implantation in a humanartery.
 8. The device of claim 1 wherein the diaphragm is approximately15 μm thick.
 9. The device of claim 1 wherein the substrate isapproximately 50 μm thick.
 10. The device of claim 1 wherein thesubstrate is configured as an antenna.
 11. The device of claim 1 whereinthe device is configured to measure pressure with a linear sensitivityof approximately four percent between 0 and 400 mm Hg.
 12. The device ofclaim 1 wherein the substrate and the diaphragm are biocompatible. 13.The device of claim 1 wherein the device is configured as a pressuresensor.
 14. The device of claim 1 wherein the device is configured as anaudio wave sensor.
 15. The device of claim 1 wherein the device isconfigured as a chemical sensor.
 16. The device of claim 1 wherein thedevice is configured as a biological sensor.
 17. The device of claim 1wherein the device is configured as an optical sensor.
 18. The device ofclaim 1 wherein the device is configured as a pump.
 19. The device ofclaim 1 wherein the device is configured as a valve.
 20. The device ofclaim 1 further comprising a first electrode coupled to the diaphragmand a second electrode coupled to the substrate.
 21. A method offabricating a thin film capacitive transducer, the method comprising;providing a substrate; providing a diaphragm, wherein the diaphragm isbetween 10 μm and 20 μm thick; and coupling the diaphragm to thesubstrate.
 22. The method of claim 21 wherein coupling the diaphragm tothe substrate comprises using adhesive to couple the diaphragm to thesubstrate.
 23. The method of claim 21 further comprising inserting achamber structure between the diaphragm and the substrate beforecoupling the diaphragm to the substrate.
 24. The method of claim 23wherein the diaphragm and chamber structure are constructed usingphotolithography.